Modular packaging



Dec. 5, 1967 J. M. PEZELY, JR 3,356,209

MODULAR PACKAG I NG Filed Aug. 24, 1964 2 Sheets-Sheet 1 INVENTOR.

JOSEPH M PEZELY J R.

%;@,W%/ @gmw Dec. 5, 1967 J, M. PEZELY, JR 3,356,209

MODULAR PACKAGING Filed Aug. 24; 1964 2 Sheets-Sheet 2 INVENTOR. JOSEPH Mv PEZELY,JR.

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A TTOR NE us United States Patent York Filed Aug. 24, 1964, Ser. No. 391,513 2 Claims. (Cl. 206-46) The present invention-relates to improvements in the packaging art, and more specifically to a novel construction for packaging fragile or breakable articles which are subject to damage during shipment.

While many different types of packaging materials and constructions have been proposed and used for protecting fragile articles during shipment, none have proved to be entirely satisfactory. Shredded paper and foam spaghetti are two types of materials commonly used to protect fragile goods; but these materials often migrate to various parts of the package, and hence, are undependable.

Corrugated materials are also widely used for protecting breakable items; but these materials have relatively poor shock absorbing characteristics, and consequently, are not always satisfactory.

The problems associated with shredded paper, foam spaghetti, and corrugated materials are overcome by employing custom-molded foam cushioning pads for supporting fragile goods in packages. However, several additional problems are raised by such packaging devices. One disadvantage of such packaging is that it is expensive due to high tool and mold costs, especially where the item to be shipped is made in small quantity. Another disadvantage is that the custom-molded pads must be specially ordered and specially made, requiring long lead times, that is, a long waiting time between the time of the order until the pads are delivered.

In view of the foregoing, it is an object of the present invention to provide a packaging construction which is inexpensive and simple to assemble and use, yet reliable and effective for protecting fragile articles from shocks encountered during shipping and handling.

It is another object of this invention to provide a packaging construction which has the desirable packaging features associated with custom-molded cushioning pads, but which, unlike the custom-molded pads, is relatively inexpensive and does not require long lead times from order to delivery.

Other objects of the invention will be pointed out in the following description and claims and illustrated in the accompanying drawings, which disclose, by way of example, the principle of the invention and the best mode which has been contemplated of applying that principle.

In the drawings:

FIGURES 1-3 are perspective views of three types of supporting panels which may be used in the present invention;

FIGURES 48 are perspective views of five different types of modules which may be used in the present invention;

FIGURES 9l2 show, in perspective, four examples of modular packaging constructions constructed in accordance with the present invention; and

FIGURE 13 shows, in perspective with parts broken away, an example of a modular packaging construction of this invention disposed in a shipping carton.

Referring now to the drawings, wherein like reference characters designate like or corresponding parts, there is shown in FIGURES l and 2 examples of a supporting panel 10 provided with holes 12 which may be die-cut therein. The panel is preferably fabricated of a shock absorbing material, such as corrugated panels. The panels 3,356,209 Patented Dec. 5, 1967 may be fabricated of any type of corrugated composition or flute size. Other relatively rigid and inexpensive panel materials may also be used, such as foam blocks, foam sheet, paper, chipboard, etc.

The modified embodiment of the supporting panel of FIGURE 3 shows a panel 14 scored and folded along two lines 16 and 18 to provide a single supporting panel having three walls.

In FIGURES 48, five shapes of the plug-in pads or blocks to be used in conjunction with the supporting panels to form a protective package are shown. The plugin blocks may be fabricated of a shock absorbing packing material which is non-abrasive, rigid enough to hold the item being shipped, has predictable performance characteristics, has good cushioning properties, is capable of withstanding repeated shocks and is relatively inexpensive. Expanded polystyrene has been found to be a satisfactory material satisfying these requirements.

Each of the plug-in blocks or cushioning pads 20, 22, 24, 26 and 28 are provided with a projection 30 which may be inserted or plugged into one of the holes 12 cut in the supporting panels. These pads may be considered to be modules. The foam pad modules of FIGURES 48 illustrate five of many different shapes in which these cushioning pads may be molded; module 20 being a corner pad, module 22 an angle pad, module 24 a low pad, module 26 a high pad, and module 28 an end pad. Any or all of these modules may be kept in stock, depending upon the frequency with which they are used. Custommolded pads or modules, such as pad 32 shown in FIG- URE 11, may also be employed in combination with standard pads when and where desirable. The shape, thickness, foam density, surface texture (for gripping the item to be shipped), color, etc., of the modules may, of course, vary depending upon the intended use. The use of the modules permits the packaged item to be cushioned only where needed, that is, at its corners or key edges.

When it is desired to package an item, two corrugated supporting panels (top and bottom, or left and right sides) of appropriate size and having slots or holes so spaced as to accommodate foam modules in desired positions, are selected. Next, modules of appropriate shape are selected, ordered from off the shelf, and mounted on the supporting pnaels by inserting the knob 30 of each module into the proper hole or slot 12 of a supporting panel. FIGURES 9l2 show examples of various combinations of the modules shown in FIGURES 48 assembled with various supporting panels.

The assembled supporting panels and modules are then placed around an article 40 to be packaged, and (as shown in FIGURE 13) the article is inserted in a preselected shipping carton, which may be made of corrugated material. The shipping carton should be large enough to accommodate the item to be packaged as well as the modules. For example, if the modules are oneinch thick, the shipping carton should be greater in size than the item to be packaged by one inch in all directions.

The fragile or breakable article so surrounded by the panel supported foam modules, and so placed in the shipping carton, is now ready for shipment. Since each foam module has a predictable performance for absorbing shock, there is a virtual guarantee against breakage.

The packaging construction of the present invention may be employed in packaging furniture, electronic instruments, industrial components and equipment, and any other items which demand maximum cushioning protection at minimum cost.

While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiment, it will be understood that various omissions and substitutions and changes in the form and details of the device illustrated and in its operation may be made by those skilled in the art without departing from the spirit of the invention. It is the intention, therefore to be limited only as indicated by the scope of the following claims.

What is claimed is:

1. An improved packaging construction for cushionably packaging frangible articles comprising, a supporting panel, said panel having a plurality of predetermined spaced-apart hole portions formed therein, a plurality of foam plastic shock absorbing blocks removably positioned in rigid spaced-apart relation on said supporting panel, each said shock absorbing block having an integral projection positioned within one of said hole portions, and each said projection being substantially the same size and shape as its associated hole portion to complement such hole portion and orient said block in a desired relative positionment on said supporting panel.

References Cited UNITED STATES PATENTS 3,064,801 11/1962. Linnell 20646 3,173,535 3/1965 Wood 20646 3,192,680 7/1965 Mantell 20646 JOSEPH R. LECLAIR, Primary Examiner.

LOUIS G. MANCENE, Examiner. 

1. AN IMPROVED PACKAGING CONSTRUCTION FOR CUSHIONABLY PACKAGING FRANGIBLE ARTICLES COMPRISING, A SUPPORTING PANEL, SAID PANEL HAVING A PLURALITY OF PREDETERMINED SPACED-APART HOLE PORTIONS FORMED THEREIN, A PLURALITY OF FOAM PLASTIC SHOCK ABSORBING BLOCKS REMOVABLY POSITIONED IN RIGID SPACED-APART RELATION ON SAID SUPPORTING PANEL, EACH SAID SHOCK ABSORBING BLOCK HAVING AN INTERGRAL PROJECTION POSITIONED WITHIN ONE OF SAID HOLE PORTIONS, AND EACH SAID PROJECTION BEING SUBSTANTIALLY THE SAME SIZE AND SHAPE AS ITS ASSOCIATED HOLE PORTION TO COMPLEMENT 